Package, carton and blanks for forming the same

ABSTRACT

A carton for articles includes a top wall, a pair of opposed end walls and a strap handle by which the carton can be carried. The strap handle is formed from part of the top wall and is connected to the end walls. The strap handle is detachable from the top wall such that detachment of the strap handle splits a remaining part of the top wall into two portions. The carton further comprises at least one bracing panel secured to the two portions of the top wall and is structured and arranged to provide a connection between the two portions.

This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/295,586, entitled “PACKAGE, CARTON AND BLANKS FOR FORMING THE SAME”, filed on Jan. 15, 2010 under 35 U.S.C. §111(b), the entirety of which is incorporated herein by reference.

The invention relates to a carton and package having a carrying handle, one or more blanks for forming the carton and a method of forming the cartons from the one or more blanks. More particularly, but not exclusively, the invention relates to a strap handle that can be lifted above a top panel of a carton and which is attached at its ends to the carton and a reinforcing brace secured to the top panel to maintain the structural integrity of the carton.

BACKGROUND OF THE INVENTION

In the field of packaging, it is often required to provide consumers with a package comprising multiple primary product containers, Such multi-packs are desirable for shipping and distribution and for display of promotional information. Such packages are often provided with carrying handles to assist in the transportation of the package of multiple products from a retail outlet to the consumer's home. Carrying handles take different forms and some of the considerations in creating a handle include: strength and durability of the carton and handle (failure of the handle could be dangerous and expensive if the contents are broken); efficient use of material in the handle (for cost and environmental reasons); ease of deployment and use; cushioning of a user's hand and ability for the handle to be re-used.

Strap handles are very easy to use because a strip of material is provided which can rise above the top panel of a carton making it very accessible for a user. However, creation of such strap type handles in a carton can cause significant weakening of the structural integrity of the carton. An example of a strap handle is disclosed in EP 0 341 089, wherein a multipack having a composite top wall formed from a pair of top panels is disclosed. The outermost top panel has a strap handle and the innermost top panel provides structural integrity to maintain the rigidity of the carton when the handle is deployed. A disadvantage of this type of carton or handle arrangement is that a substantial amount of material is required to form the two top panels, making the overall carton expensive to produce and less environmentally friendly.

The present invention seeks to mitigate these and other problems associated with the prior art and/or provide an improvement in the field of carton package handles.

SUMMARY OF INVENTION

According to a first aspect, the invention provides a carton for articles having a strap handle by which the carton can be carried, the strap handle being formed from part of a top wall of the carton and being connected to end walls of the carton, the strap handle being detachable from the top wall of the carton such that detachment of the strap handle splits the top wall into two separate portions, and the carton comprises a bracing panel secured to the top wall of the carton and being structured and arranged to provide a connection between the two separate portions of the top wall.

Preferably, the strap handle is defined by one or a combination of a pair of frangible lines and a pair of cut-lines in the top wall of the carton.

Preferably, the bracing panel is secured to an inside face of the top wall and is free of attachment to the strap handle.

Preferably, the bracing panel is secured by adhesive to an inside face of the top wall at the edges of the top wall such that the bracing panel is only attached to the two separate portions of the top wall to connect those two portions.

Preferably, each end wall comprises a relief mechanism to assist the free movement of the strap handle out of the plane of that end wall.

Preferably, the relief mechanism of each end wall comprises one or more or a combination of a terminating frangible line, a terminating cut-line or a notched cut-out formed in that end wall.

Optionally, the strap handle is defined by a pair of severance lines in the top wall, wherein each end wall is a composite structure comprising major and minor end flaps, wherein the relief mechanism of each end wall comprises a pair of terminating severance lines in the minor end flaps of that end wall as extensions of the pair of severance lines in the top wall and wherein the relief mechanism of each end wall further comprises a pair of severance lines in the major end flaps of that end wall. The severance lines in the major end flaps of each end wall are disposed in alignment with the terminating severance lines in the minor end flaps of that end wall.

Optionally, the strap handle is defined by a pair of severance lines in the top wall, wherein the end wall is a composite structure comprising major and minor end flaps, wherein the relief mechanism of each end wall comprises a pair of terminating severance lines in the minor end flaps of each end wall as extensions of the pair of severance lines in the top wall, and wherein the relief mechanism in each end wall further comprises a pair of notched cut-outs of the major end flaps of that end wall. The notched cut-outs of each end wall are disposed adjacent to the terminating severance lines in the minor end flaps of that end wall.

Optionally, the carton comprises more than one bracing panel and/or comprises more than one strap plies forming the strap handle.

According to a second aspect, the invention provides a pair of blanks for forming a carton having a strap handle, one of the blanks comprising a series of main panels for forming the body of the carton including one or more top panels for forming the top wall of the carton, the top panels defining one or more strap plies therein for forming the strap handle, the one or more strap plies being detachable from the one or more top panels such that detachment of the strap plies splits the top wall into two separate portions when the blanks are erected into the carton, and the other of the blanks comprising a bracing panel securable to the one or more top panels for providing a connection between the two separate portions of the top wall.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a plan view of a first blank for forming a carton having a carrying handle according to a first embodiment of the invention;

FIG. 1B is a plan view of second blank for forming an insert for the blank of FIG. 1;

FIG. 2 is a plan view of the blank of FIG. 1 showing the position of the insert of the second blank of FIG. 1B and showing the locations of some adhesive used to secure the panels of the carton blank;

FIG. 3 is a plan view from above of a first step in the folding and securing sequence to form a carton having a carrying handle from the blanks of FIGS. 1A and 1B;

FIG. 4 is a is a plan view from above of a second step in the folding and securing sequence to form a carton having a carrying handle from the blanks of FIGS. 1A and 1B;

FIG. 5 is a perspective view from the top, side and end of a carton formed from the blanks of FIGS. 1A and 1B in its fully formed state; with its handle deployed and with both its handle deployed and an optional opening mechanism deployed;

FIG. 6 is a perspective view from the top, side and end of a carton formed from the blanks of FIGS. 1A and 1B being carried by the strap handle;

FIG. 7 is a plan view of a first blank for forming a carton having a carrying handle according to a second embodiment of the invention; and

FIG. 8 is a perspective view from the top, side and end of a carton formed from the blanks of FIGS. 7 and 1B with the strap handle deployed.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

Detailed descriptions of specific embodiments of the package, blanks and cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Referring to FIG. 1, a blank 10 formed of foldable sheet material, in this example paperboard, is shown comprising: first top panel 12 a; first side panel 14; bottom panel 16, second side panel 18 and second top panel 12 b. These main panels are hinged one to the next in series along fold lines 52, 54, 56 and 58 and are foldable and securable into a tubular structure to form a carton 11 (see FIGS. 5 and 6) of the fully enclosed end loading type. Composite end walls are formable to close the ends of the carton 11, the composite end walls comprise major end flaps 22, 26, 32, 36 hinged to each end of the side walls 14, 18 and minor end flaps 20, 24, 28, 30, 34, 38 hinged to each end of the top and bottom panels 12 a, 12 b, 16. The major end flaps 22, 26, 32, 36 and minor end flaps 20, 24, 28, 30 are hinged along fold lines 62, 66, 72, 76, 60, 64, 68, 70, 74 and 78 respectively.

A handle arrangement is formed in part in first and second top panels 12 a, 12 b and in part by a secondary insert formed from a second blank 8 shown in FIG. 1B. The handle arrangement comprises a strap handle. In this illustrated arrangement, the strap handle is formed of two plies of material 86, 84 formed in the first and second top panels 12 a, 12 b respectively. Each strap-ply 84, 86 is defined by an edge of the associated first or second top panel 12 a, 12 b and by a severance line (such as a cut-line or a perforate line) 44, 46. Each strap-ply 84, 86 is contiguous with and formed as part of the adjacent minor end flap 20, 30, 28, 38 hinged to each end of the first and second top panels 12 a, 12 b respectively.

A relief mechanism, in the form of terminating severance lines 44 b, 44 a, 48 b, 48 a define the termination of the strap-ply 84, 86 in the minor end flaps 20, 30, 28, 38 and allow the strap handle once fully formed to move relative to a part of the minor end flap 20, 30, 28, 38 that is secured to an adjacent major end flap 22, 26, 32, 36 and thus the composite end wall. To further facilitate the movement of the strap handle relative to the remainder of the carton, a further relief feature is provided in the form of severance lines or notches 80, 82, 88, 90 formed in each major end flap 32, 22, 26, 36 close to an end edge of that major end flap 32, 22, 26, 36. In this way, when the carton is constructed, the relief feature 80, 82, 88, 90 is aligned with the terminating severance line 44 a, 44 b, 48 a, 48 b that is itself disposed close to the composite top wall and the composite strap handle H formed from the two strap plies 84, 86 is able to extend above the top walls 12 a, 12 b into a use position.

The second part of the handle arrangement is provided by a substantially rectangular bracing panel 8 (see FIG. 1B) that is sized to fit the width of the composite top wall once completed and provide a secure connection and reinforcing brace between the first and second top panels 12 a, 12 b. In this example, the bracing panel 8 spans approximately a third of the length of the top panels 12 a, 12 b. Though the bracing panel 8 does not form part of the moveable strap handle H, it provides a connecting reinforcement between the two top panels 12 a, 12 b which become separated once the handle is deployed, (or before the handle is deployed, as in the present case).

As a preferable, yet nevertheless optional feature, the strap-plies 84, 86 each comprise a handle cushioning element 50 a, 50 b formed as a foldable handle flap hingeable about a central portion of the strap-plies 84, 86. When the carton is constructed and the strap-plies 84, 86 overlaid, the cushioning flaps 50 a, 50 b are disposed directly opposite one another on each side of the strap handle H so that a user's hand is simultaneously cushioned by each flap when the handle is used (see FIG. 6).

As yet a further preferable, yet nevertheless optional feature, the blank 10 is illustrated as having an optional access means formed in part in the side walls 14, 18 and in part in the major end flaps 32, 36 hinged thereto. The access means is defined by perforate or frangible lines 42 a, 42 b which define removable portions 40 a, 40 b. Once the removable portions 40 a, 40 b have been removed, sequential access to individual articles is achieved (see FIG. 5).

Turning to the construction of the carton, as is illustrated in FIGS. 2, 3 and 4 it is envisaged that the carton can be formed by a series of sequential folding operations in a straight line machine so that the carton is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

Optionally, the panels of the carton once folded into position are secured by adhesive. Possible adhesive areas G1, G2, G3, G4, G6, G8, G10, G12, G14, G16 and G18, where glue could be applied in order to secure together the panels of the carton are shown in lined and hashed form in FIG. 2. Other mechanisms may be used for securing the panels and/or other positions of the adhesive may be used. The adhesive areas shown in some instances are relative positions, i.e. the glue may be applied to one or the other or both of two panels that are to be secured together. The foregoing description should not be construed as limiting in this respect, but merely provides an example of one way in which the carton 11 can be constructed from the blank 10.

In the exemplary construction process described, glue is applied to either top panel 12 a or insert 8 in the approximate area denoted by G1. Preferably, the adhesive is applied to the blank 10 on panel 12 a and that panel 12 a is kept stationary whilst bracing insert 8 is brought into physical alignment with top panel 12 a and adhered thereto. By sizing bracing insert 8 to match the width between fold lines 52 and 58 once the two top panels 12 a, 12 b have been overlaid, the alignment of bracing insert 8 is made easier as the edge of the bracing insert 8 should be disposed immediately adjacent to the fold line 52 (see FIG. 2).

First top panel 12 a, together with the attached bracing insert 8 (which is secured to the inside surface of the top panel 12 a) are folded about fold line 52 and into face contacting relationship with first side panel 14. This position is illustrated in FIG. 3. Adhesive area G16 illustrated in hashed format illustrates the approximate location of the adhesive between the second top panel 12 b and insert 8. Preferably, the adhesive is applied in region G16 onto bracing insert 8 and then the second top panel 12 b is folded about fold line 58 so that the strap-ply 84 overlays strap ply 86 and so that a portion of second top panel 12 b is overlaid and attached to the insert 8. FIG. 4 illustrates the folded and secured position of the second top panel 12 b. It can be seen that a composite top wall has been created wherein the insert is disposed at the bottom and adjoined by means of adhesive in areas G1 and G16 to each of the first and second top panels and the strap-ply 86 of the first top panel 12 a is disposed beneath the strap-ply 84 of the second top panel 12 b. Preferably, the strap-plies 84, 86 are secured together by adhesive applied in the region of G18. In this way minor end flaps 20 and 28 and 30 and 38 are connected.

The part-formed structure of FIG. 4, the folded and pre-glued blank, may be shipped in this format to a converting plant whereat the part-formed blank is opened into a tubular structure and loaded through one or both ends with articles such as cans or bottles. Once fully loaded, the major and minor end flaps 22, 26, 32, 36, 20, 24, 28, 30, 34, 38 are folded and adhered to form composite end walls. Preferably the minor flaps 20/28, 24 and 30/38, 34 are folded first so that they are disposed closer to the inside of the carton than the major flaps 22, 26, 32, 36 which are then disposed outermost.

The completed carton 11 is shown in FIGS. 5 and 6. To deploy the handle the user may grasp a medial portion of the strap handle H and separate that strap handle H from the remainder of the composite top wall. The separation or detachment of the strap handle H from the composite top wall splits the top wall into two spaced portions 12 a, 12 b. The insert brace 8 maintains a secure connection between the these two spaced portions 12 a, 12 b of the composite top wall and thereby maintains the structural integrity and robustness of the carton despite the splitting of the top wall by the strap handle H (84, 86).

Referring now to FIG. 7 and FIG. 8, an alternative embodiment of the present invention is illustrated in which like numerals have, where possible, been used for like parts, with the addition of the prefix “1” to denote like features of the first and second embodiments. Only the differences from the embodiment illustrated in FIGS. 1 to 6 will be described in detail.

The main difference between this arrangement and the previous handle arrangement is the use of notched cutouts 180, 182, 188, 190 which facilitate the unhampered deployment of the strap handle H. The strap handle H is able to move upwardly from the top panel 112 a/112 b by virtue of the fact that the ends of the strap handle H cut across the corner of the carton and thus shorten the distance travelled by the strap handle at its ends thus providing some slack in the central region above the top wall. The notched cut-outs 180, 182, 188, 190 ensure that when the end parts of the handle move away from the fixed parts of the composite end wall that the ends of the handle can be moved in an unhindered manor (see FIG. 8).

It can be appreciated that various changes may be made within the scope of the present invention, for example, the size and shape of the panels may be adjusted to accommodate articles of differing size or shape. Whereas the handle arrangement has been shown as beneficial in a carton of the fully enclosed end-loading type, it will be understood that the handle arrangement is applicable to be used with other styles, sizes and configurations of cartons including, partially enclosed cartons, bottom loading cartons, wrap around cartons and clips to list some of many examples.

It is envisaged that in some embodiments only a single top panel is provided. In such arrangements, one or more reinforcing strap plies may be hinged to the minor end flaps of the single top panel and be foldable into alignment with the strap-ply of the single top panel. In some embodiments, the brace panel 8 may be provided as an integral part of blank 10 rather than as a separate insert feature provided by a second blank. In such embodiments, the brace panel 8 may be hinged and connected to either the first or second top panel 12 a, 12 b or to a single top panel. In any or each of these arrangements, the brace panel 8 may be foldable into its reinforcing or bracing position and securable in that position by means of adhesive or further overlaying panels. In such arrangements the nesting area of the overall single blank may cause unnecessary wastage and the two-blank arrangement illustrated may offer the advantage that less material is wasted, however the integral blank arrangement may offer benefits in ease of manipulation during construction. In some embodiments more than one bracing panel is used. In some embodiments the bracing panel is disposed in an off-centre position.

In other embodiments, there may be fewer or greater than two strap plies and/or the or each strap-ply may be defined by one or more of: a panel edge, a cut-line, a perforate line, a pair of cut-lines or a pair of perforate lines. Indeed each strap handle may be defined by a combination of perforate and cut-lines, for example, in the region of the bracing panel 8, the or each strap ply 84, 86 may be defined by a severance line. This could make accessing the strap handle easier for a user and yet will not provide an entrance for dust into the carton because of the presence of the bracing panel 8. The remainder of the line 44, 46 defining the handle strap-plies 84, 86 may be perforated to ensure that the integrity of the top panel is maintained during transportation and storage and the carton sealed from dust until a consumer is ready to operate the handle by breaking that frangible connection.

As a preferred option, the strap plies 84, 86 each comprise a handle cushioning element 50 a, 50 b. Such handle cushioning flaps are well known and may take various shapes, sizes and formats. Handle cushioning elements other than foldable handle flaps may be used in other embodiments. In yet an alternative embodiment, no handle cushioning elements are provided. The cushioning handle flaps may be accompanied by or replaced by handle apertures adjacent to the strap handle H to facilitate the user's grasping of the strap handle H.

It will be understood that a wide variety of access means or that no tear-out access means may be provided in other carton embodiments utilising the beneficial handle arrangement of the present invention.

In other embodiments of the invention mechanical fastening means such as staples, pins and the like may be used as well as or instead of adhesive. Where adhesive is used, this may be a hot-melt glue, pressure activated glue or any other adhesive. A wide variety of suitable adhesives are available.

Though the bracing panel 8 has been illustrated as rectangular in shape and about a third of the size of the top panel in dimension, it will be understood that a variety of shapes and sizes of bracing panel will be suitable for maintaining a secure connection between the two spaced portions of the top panel that are created by the strap handle H bisecting the top wall of the carton as the handle is deployed or before the deployment (in the case where the strap-plies are defined by severance lines (e.g., cut lines or perforate lines). The bracing panel 8 may also be positioned in a variety of places providing that it connects the two separate portions of the top wall.

Whereas the strap-handle has been described and illustrated as extending substantially centrally in a longitudinal direction across the top wall between the end walls, it will be understood that the strap handle may be positioned off centre, that for larger cartons more than one off-set strap handle may be provided and that in some embodiments, the strap handle or handles may extend in a substantially transverse direction between the side walls and in some embodiments, the strap handle or handles may extend at an angle rather than substantially normal to the adjacent walls of the carton.

It will be recognised that as used herein, directional references such as “top”, “bottom”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another. Any reference to hinged connection should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that hinged connection can be formed from one or more of the following, a short slit, a frangible line or a fold line without departing from the scope of the invention. 

1. A carton for articles, comprising a top wall, a pair of opposed end walls and a strap handle by which the carton can be carried, the strap handle being formed from part of the top wall and being connected to the end walls, the strap handle being detachable from the top wall such that detachment of the strap handle splits a remaining part of the top wall into two portions, and the carton further comprises at least one bracing panel secured to the two portions of the top wall and being structured and arranged to provide a connection between the two portions.
 2. A carton according to claim 1 wherein the strap handle is defined by one of a pair of frangible lines and a pair of cut-lines in the top wall.
 3. A carton according to claim 1 wherein the strap handle is defined by a combination of a pair of frangible lines and a pair of cut-lines in the top wall.
 4. A carton according to claim 1 wherein the at least one bracing panel is secured to respective inside faces of the two portions and is free of attachment to the strap handle.
 5. A carton according to claim 4 wherein the at least one bracing panel is secured by adhesive to the inside faces of the two portions along the opposed side edges of the top wall such that the at least one bracing panel is only attached to the two portions of the top wall to connect the two portions.
 6. A carton according to claim 1 wherein each of the end walls comprises a relief mechanism to assist free movement of the strap handle out of the plane of the end wall.
 7. A carton according to claim 6 wherein the relief mechanism comprises at least one of a terminating frangible line, a terminating severance line and a notched cut-out formed in a respective one of the end walls.
 8. A carton according to claim 6 wherein the strap handle is defined by a pair of severance lines in the top wall, wherein the each end wall is a composite structure comprising major and minor end flaps, wherein the relief mechanism of the each end wall comprises a pair of terminating severance lines defined in the minor end flaps of each end wall as respective extensions of the severance lines in the top wall, and wherein the relief mechanism of the each end wall further comprises a further pair of severance lines formed in the major end flaps of the each end wall, the severance lines in the major end flaps of the each end wall are disposed in alignment with the terminating severance lines in the minor end flaps of the each end wall.
 9. A carton according to claim 6 wherein the strap handle is defined by a pair of severance lines in the top wall, wherein the end wall is a composite structure comprising major and minor end flaps, wherein the relief mechanism of the each end wall comprises a pair of terminating severance lines defined in the minor end flaps of the each end wall as respective extensions of the severance lines in the top wall, and wherein the relief mechanism of the each end wall further comprises a pair of notched cut-outs of the major end flaps of the each end wall, the notched cut-outs of the each end wall are disposed adjacent to the terminating severance lines in the minor end flaps of the each end wall.
 10. A carton according to claim 1 wherein the at least one bracing panel comprises two or more bracing panels each secured to the two portions of the top wall.
 11. A carton according to claim 1 wherein the strap handle comprises two or more strap plies of sheet material secured together.
 12. A pair of blanks for forming a carton having a strap handle, one of the blanks comprising a series of main panels for forming a body of the carton including one or more top panels for forming a top wall of the carton, the one or more top panels defining one or more strap plies therein for forming the strap handle, the one or more strap plies being detachable from the one or more top panels such that detachment of the one or more strap plies splits a remaining part of the top wall into two portions when the blanks are erected into the carton, and the other of the blanks comprises a bracing panel securable to the one or more top panels to provide a connection between the two portions.
 13. A pair of blanks according to claim 12 wherein the one or more top panels comprise two top panels, and the one or more strap piles comprise two strap piles formed respectively from respective parts of the two top panels, each of the two strap piles being defined by at least one of a frangible line and a cut-lines in the top wall. 